Process and apparatus for the production of synthesis gas

ABSTRACT

Reactive diluent fluid ( 22 ) is introduced into a stream of synthesis gas (or “syngas”) produced in a heat-generating unit such as a partial oxidation (“PDX”) reactor ( 12 ) to cool the syngas and form a mixture of cooled syngas and reactive diluent fluid. Carbon dioxide and/or carbon components and/or hydrogen in the mixture of cooled syngas and reactive diluent fluid is reacted ( 26 ) with at least a portion of the reactive diluent fluid in the mixture to produce carbon monoxide-enriched and/or solid carbon depleted syngas which is fed into a secondary reformer unit ( 30 ) such as an enhanced heat transfer reformer in a heat exchange reformer process. An advantage of the invention is that problems with the mechanical integrity of the secondary unit arising from the high temperature of the syngas from the heat-generating unit are avoided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 13/774,833, filed on Feb. 22, 2013, which is acontinuation of U.S. patent application Ser. No. 12/704,311, filed onFeb. 11, 2010, which is a continuation of U.S. application Ser. No.10/518,038 (now U.S. Pat. No. 7,670,586), filed on Dec. 13, 2005, whichis a national stage application of International ApplicationPCT/IB03/00695, filed on Feb. 24, 2003, which is a continuation of andclaims priority to U.S. application Ser. No. 10/083,778, filed on Feb.25, 2002, the entire disclosures of which are incorporated herein byreference.

BACKGROUND

The present invention relates to a process and apparatus for theproduction of synthesis gas, particularly for but not necessarilylimited to, use in the production of hydrocarbon liquid fuels (e.g.using the Fischer-Tropsch (“F-T”) process), methanol (e.g. by catalytichydrogenation of carbon monoxide), oxo-alcohols and dimethyl ether(“DME”).

Natural gas may be found in remote locations both on- and offshore. Itis generally expensive and impractical to transport natural gas from itssource to a distant processing plant. One solution is to convert the gason-site to a valuable and easily transportable product. In this way, thevalue of the natural gas may be increased.

Natural gas may be converted to synthesis gas (or “syngas”) which is amixture of carbon monoxide and hydrogen. Syngas may be converted to asolid or liquid synthetic fuel (“synfuel”) or converted to methanol,oxo-alcohols or DME. For optimum conversion in the F-T process, theratio of hydrogen to carbon monoxide is preferably about 2 to 1. Theconversion products have less volume per unit mass (i.e. have a greaterdensity) than the natural gas. Accordingly, it is more economical totransport conversion products than a corresponding amount of naturalgas.

Syngas may be produced using a heat exchange reforming (“HER”) process.A conventional two-step HER process may use natural gas as feedstock andemploys a primary exothermic (or heat-generating) unit producing syngas,e.g. from natural gas and oxygen, coupled with a secondary endothermic(or heat-requiring) unit that uses at least a portion of the heatgenerated in the primary unit to produce further syngas, e.g. by areforming reaction of natural gas and steam. In certain HERs, the syngasgenerated by the HER feeds the primary exothermic unit, while other HERsoperate in parallel to the exothermic unit and augment the syngasproduction therein.

There are several methods of producing syngas from natural gas. Examplesof these methods include:

(a) Steam-methane reforming (“SMR”) which uses an endothermic catalysedreaction between natural gas and steam. There is a need to import carbondioxide or otherwise remove excess hydrogen to achieve the requiredratio of 2 to 1 for the relative proportions of hydrogen and carbonmonoxide in the resultant syngas. In many applications (including F-Tprocesses, methanol synthesis and other chemical processes), such anopportunity to import carbon dioxide and/or export any separated excesshydrogen may not be available and/or economical;

(b) Partial oxidation (“PDX”) of natural gas with pure oxygen whichachieves a hydrogen to carbon monoxide ratio in the resultant syngas inthe range from 1.6-1.8 to 1. Imported hydrogen is needed to achieve thatrequired ratio of 2 to 1 for the relative proportions of hydrogen andcarbon monoxide in the resultant syngas;

(c) Autothermal reforming (“ATR”) which uses a partial oxidation burnerfollowed by a catalyst bed with a feed of natural gas, steam and oxygento produce the required 2 to 1 ratio for the relative proportions ofhydrogen and carbon monoxide in the resultant syngas; and

(d) Catalytic partial oxidation (“CPO”) which is the reaction of naturalgas with oxygen over a catalyst that permits flameless partialcombustion to hydrogen and carbon monoxide in the required relativeproportions in the resultant syngas.

For PDX, ATR and CPO, the oxidation reaction in the primaryheat-generating unit is exothermic and, thus, the syngas is produced atelevated temperature. For example, PDX produces syngas at a temperatureof from 1200 to 1400° C., ATR produces syngas at a temperature of from900 to 1100.degree. C. and CPO produces syngas at a temperature of from1000 to 1100.degree. C.

The excess heat generated in these processes may be used to generatesteam, for example in waste heat boilers, that can be used in steamturbines to generate power for air separation systems, air compressorsand other equipment.

The excess heat may be used with additional natural gas and steam in aseparate secondary unit to generate further syngas via steam-methanereforming. This process is the basis of the generic two-step HERprocess. In such a process, the high temperature syngas from the primaryheat-generating unit is usually introduced to the shell-side of a shelland tube style steam-methane reformer. The tubes may containconventional steam-methane reforming catalyst over which natural gas andsteam react endothermically to form syngas. The heat from syngas on theshell-side of the reformer is used to drive the endothermicsteam-methane reforming reaction. The syngas stream leaving the tubescan be separately collected and used to feed the primary exothermicsyngas generator. Preferably, however, the syngas streams leaving thetubes are combined with the syngas on the shell-side to produce syngashaving the desired ratio of hydrogen to carbon monoxide at a temperatureof from 500 to 600.degree. C.

A secondary unit in which reforming takes place over catalyst using heattaken from the primary heat-generating unit is known as a Heat ExchangeReformer. One such example is described in U.S. Pat. No. 4,919,844(Wang; published on 24, Apr. 1990) and is called an Enhanced HeatTransfer Reformer (or “EHTR”). The disclosure of this patent isincorporated herein by reference. Other existing HER processes aredisclosed in WO-A-98/32817 (Halmo et al; published on 30, Jul. 1998),WO-A-00/09441 (Abbot; published on 24, Feb. 2000), WO-A-00/03126(Fjellhaug et al; published on 20, Jan. 2000) and U.S. Pat. No.5,362,453 (Marsch; published on 8, Nov. 1994). These disclosures arealso incorporated herein by reference.

An example of an HER process is disclosed in U.S. Ser. No. 09/965,979(filed on 27, Sep. 2001 and claiming priority from GB0025150.4 filed on13, Oct. 2000) and this disclosure is incorporated herein by reference.In this example, a PDX reactor is used in combination with an EHTR.Hydrocarbon fuel gas is reacted with steam and/or oxygen gas in a syngasgeneration system to produce a syngas product stream. An oxidant gas iscompressed to produce a compressed oxidant gas, at least a portion ofwhich is combusted in the presence of combustion fuel gas to producecombustion product gas. The combustion product gas is expanded toproduce power and expanded combustion product gas. Heat from theexpanded combustion product gas is recovered by using the expandedcombustion product gas to heat steam by heat exchange to produce heatedsteam, at least a portion of which is used to provide at least a portionof any steam requirement for producing the syngas product stream in thesyngas generation system. Additionally or alternatively, at least aportion of the oxygen gas is provided using an ASU that is driven by atleast a portion of the power generated by the expansion of thecombustion product gas.

Syngas product feeding conversion processes will unavoidably containcarbon dioxide. For F-T synfuel processes that use cobalt catalysts,this carbon dioxide behaves like an inert. Whilst it can be venteddownstream, the carbon and oxygen capture efficiency of the entire gasto liquid (“GTL”) process is lower, which contributes to the greenhouseeffect. It is thus desirable to recycle this carbon dioxide to thefront-end syngas generator. It is a primary objective of preferredembodiments of this invention to enable efficient recycle of carbondioxide and affect its efficient conversion to useful carbon monoxide,while minimizing the amount of such recycle and usage of oxygenfeedstock.

Loss of carbon dioxide and methane from natural gas conversion processesis undesirable for several reasons. First, these gases are well known tohave “greenhouse gas” properties. Secondly, valuable carbon atoms arebeing lost to the atmosphere thereby affecting the carbon efficiency andyield of the overall processes. Therefore, it is also an objective ofpreferred embodiments of the present invention to reduce the emissionlevel of these greenhouse gases and other pollutants, for example oxidesof nitrogen (“NO.sub.x”), and to recover at least some of the valuablecarbon that is usually lost in natural gas conversion processes usingHER technology for syngas generation.

In HER processes where hot gas is introduced to the shell-side of anHER, it is undesirable for the temperature of the syngas leaving theprimary heat-generating unit to be too high as the mechanical integrityof the HER may be challenged. For example, the metal of the HER may loseits physical strength and soften. Therefore, it is another objective ofpreferred embodiments of the present invention to reduce or eliminatethe possibility of problems with the mechanical integrity of the HERresulting from excessive syngas temperature in natural gas conversionprocesses using HER technology.

The PDX process can generate syngas with small amounts of solid carbonparticles or soot. This soot could foul or erode the heat exchangesurfaces in the downstream HER. It is thus another objective of thisinvention to reduce or eliminate the potential for problems arising forsuch solid carbon particles.

U.S. Pat. No. 4,731,098 (Marsch: published on 15, Mar. 1988) discloses areformer in which natural gas and steam are reformed to produce syngas.The syngas is then mixed with natural gas and oxygen or air before themixture leaves the reformer.

Water has been used as a diluent in the production of syngas. Examplesof such use of water have been disclosed by P. Osterrieth and M.Quintana (“A New Approach to the Production of Custom-made Synthesis GasUsing Texaco's Partial Oxidation Technology”; Texaco DevelopmentCorporation; AIChE meeting Presentation, 6, Mar. 1988) and by W. FrancisFong and M. E. Quintana (“HyTEX: A Novel Process for HydrogenProduction”; Texaco Development Corporation; NPRA 89th Annual Meeting,17-19, Mar. 1991, San Antonio, Tex.)

U.S. Pat. No. 3,723,344 (Reynolds; published on 23, Mar. 1973) and U.S.Pat. No. 3,919,114 (Reynolds; published on 11, Nov. 1975) both describeprocesses for the generation of synthesis gas. The synthesis gas isproduced by the partial oxidation of hydrocarbon fuel with a freeoxygen-containing gas, optionally, in the presence of a temperaturemoderator such as steam. Carbon dioxide-rich gas or steam is combinedwith a stream of the synthesis gas product and the gaseous mixture isthen subjected to a non-catalytic water gas reverse shift reaction and aportion of the carbon dioxide in the combined stream is reduced tocarbon monoxide while simultaneously a stoichiometric amount of hydrogenis oxidized to water. Heat is removed from the resultant shift productgas in a waste heat boiler. Soot is then removed from the resultantcooled shift product gas using quench water in a gas-liquid contactapparatus. Carbon dioxide is then removed from the soot-depleted shiftproduct gas and the resultant synthesis gas is then used in thesynthesis of hydrocarbons and/or methanol.

In meeting the above-mentioned objectives, it is also important that anymodifications to existing HER processes do not affect adversely theyield of conversion products, the capital and/or operating costs and thelevel of power usage.

BRIEF SUMMARY OF THE INVENTION

It has been found that these objectives may be achieved with theintroduction of a cooling stream of reactive diluent fluid to the syngasproduced in the primary heat-generating unit to produce a cooled mixtureof syngas and reactive diluent fluid and the subsequent reaction of atleast two of the components of the mixture to either produce furthercarbon monoxide and/or to gasify solid carbon particles.

Hydrocarbon-containing fuel is exothermically reacted with an oxidantgas comprising molecular oxygen in a first reactor to produce anexothermically-generated syngas product. A stream of reactive diluentfluid is combined with a stream of said exothermically-generated syngasproduct to produce a reactive mixture and the reactive mixture isreacted in a second reactor to produce a reacted syngas product. Thereacted syngas is introduced into a secondary reforming unit in an HERprocess. One advantage of the invention is that the reacted syngasproduct is cooled before being introduced into the secondary unitthereby avoiding negatively affecting the mechanical integrity of thesecondary unit.

If the reactive diluent fluid comprises gases produced downstream in theoverall process that would otherwise be vented to the atmosphere or thatwould have to undergo treatment before venting to atmosphere, the levelof pollutant emissions to the environment may be reduced andcorresponding cost savings may be achievable from the pollutant gastreatment processes.

Carbon dioxide and hydrogen present in the reactive mixture may beconverted into water and valuable carbon monoxide. This conversion isparticularly useful when the reactive diluent fluid is carbon dioxide.However, it still has useful application when the reactive diluent fluidis not carbon dioxide but the source of hydrocarbon fuel (e.g. naturalgas) containing significant quantities of carbon dioxide. The additionalcarbon monoxide produced may be used downstream to improve the yield ofthe natural gas conversion products. If the reactive diluent fluidcomprises carbon dioxide that has been recycled from downstreamprocesses then there is a further advantage in that the level of carbondioxide emission to the environment is reduced.

If the syngas is utililized in an F-T synfuel process, the gas exitingsuch a downstream process can contain significant amounts of carbondioxide. Such gas typically also contains unconverted syngas as well aslight hydrocarbons. It is particularly advantageous to this invention torecycle such carbon dioxide-comprising gas as the reactive diluent. Suchgas can be recycled as diluent without further processing in which casethe other components (other than carbon dioxide) would participate inthe reaction, increasing the production of desired synfuel. Alternately,the carbon dioxide content of such gas can be isolated in an acid gasremoval (“AGR”) unit for recycle to the front end of the process and theother components could be used as fuel. The carbon dioxide, steam,oxygenates and molecular hydrogen in the recycled diluent canparticipate in the gasification of soot.

A reverse water gas shift reaction may be used to convert the carbondioxide and hydrogen into water and valuable carbon monoxide. Such areaction is endothermic and, thus, uses heat from the reactive mixturethereby imposing additional cooling on the syngas and assisting in theoverall ability to maintain mechanical integrity in a secondaryreforming unit of an HER process.

In existing HER processes where carbon dioxide is recycled fromdownstream processes, the carbon dioxide is fed to the tube side of theHER unit of the synthesis gas generation system. In the tubes of the HERunit, the following two reactions take place:

CO₂+CH₄→2CO+2H₂

CH₄+H₂O→CO+3H₂

Reaction (I) is thermodynamically less favourable than reaction (II) andrequires higher temperatures. The temperature at the exit of the HERtubes is necessarily lower than the temperature of the gas from theexothermic reactor. Therefore, the carbon dioxide is not completelyconverted when the syngas exits the tubes of the reformer unit. If theHER is a parallel type (such as an EHTR), this can lead to excessivecosts associated with the recycle of carbon dioxide.

According to preferred embodiments of the present invention, carbondioxide is converted to carbon monoxide in a reverse water gas shiftreaction before being fed to the secondary reformer unit. The followingreaction takes place in the reverse water gas shift reactor:

CO₂+H₂⇄CO+H₂O

Reaction (III) is in equilibrium but the position of the equilibrium ispushed far over to the right hand side due to the high temperature ofthe syngas and the continual introduction of carbon dioxide. Therefore,by recycling carbon dioxide, injecting it into theexothermically-generated syngas product produced in the primaryheat-generating unit and subjecting the reactive mixture to a reversewater gas shift reaction, more carbon dioxide may be converted to usefulcarbon monoxide. This conversion minimizes the size of the carbondioxide recycle loops and associated costs. In addition, the reverseshift reaction zone assists in the gasification of any soot in thesyngas from a PDX-type exothermic unit, mitigating any erosion orfouling concerns in the surfaces of heat exchangers downstream,including HERs, boilers and preheaters. It can also eliminate therequirement of a scrubber that normally accompanies PDX processes.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. Other features,objects, and advantages of the invention will be apparent from thedescription and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flowsheet describing one embodiment of the process of thepresent invention;

FIG. 2 is a flowsheet describing a hydrocarbon conversion process inwhich the process of FIG. 1 is integrated with a downstream genericsyngas conversion process to produce hydrocarbon liquid fuels or otherliquid products; and

FIG. 3 is a flowsheet describing another embodiment of the process ofthe present invention.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

According to one aspect of the present invention, there is provided aprocess for the production of syngas comprising carbon monoxide andmolecular hydrogen, said process comprising;

exothermically reacting hydrocarbon-containing fuel an oxidant gascomprising molecular oxygen in a first reactor to produce anexothermically-generated syngas product;

combining a stream of reactive diluent fluid with a stream of saidexothermically-generated syngas product to produce a reactive mixture;

reacting said reactive mixture in a second reactor to produce a reactedsyngas product; and

endothermically reforming hydrocarbon-containing fuel gas with steamover a catalyst in a heat exchange reformer to produce a heatexchange-reformed syngas product,

wherein at least a portion of the heat required in the generation ofsaid heat exchange-reformed syngas product is obtained by recoveringheat from said reacted syngas product thereby cooling said reactedsyngas.

The “reactive diluent fluid” includes any diluent fluid that is capableof cooling syngas by direct heat exchange and comprising at least onecomponent that may react with at least one component of the synthesisgas. The “reactive mixture” comprises cooled exothermically generatedsyngas product and reactive diluent fluid. The “reacted syngas product”includes the product syngas that has undergone a further reaction eitherto produce further carbon monoxide or to remove solid carbon particles,e.g. soot, produced as a by-product of the oxidation reaction in theprimary heat-generating unit. Thus, the present may be used for sootcontrol purposes.

The hydrocarbon fuel may be a solid or liquid fuel but it is preferablya gas. Natural gas is the preferred fuel. Pure molecular oxygen ispreferred as the oxidant gas over an oxidant gas comprising molecularoxygen such as air. Water may be present in the reaction to produceexothermnically-generated syngas product (for example, if an ATR processis used). If water is present, it may be used in liquid form in whichcase it will vaporise immediately upon entry into the first reactor.However, the use of steam is preferred.

An advantage of this invention is that the temperature of theexothermnically-generated syngas product is reduced and may becontrolled as required for downstream processing. The downstreammechanical integrity problems that may result from the high levels ofheat generated in the primary heat-generating unit may be avoided andprocess operability may be improved by controlling the reducedtemperature of the exothermically-generated syngas product.

Another advantage of this invention that any solid carbon present in theexothermically-generated syngas product can be at least partiallygasified mitigating fouling, erosion or plugging of downstream heatexchangers such as HERs, boilers or preheaters.

Where the reactive mixture comprises carbon dioxide, at least a portionof the carbon dioxide may be reacted together with at least a portion ofthe molecular hydrogen in said mixture over a catalyst in a reversewater gas shift reaction zone to produce a carbon monoxide-enrichedsyngas product.

Where the reactive mixture comprises solid carbon particles, at least aportion of the particles may be gasified by reaction with at least oneother component of the mixture in a gasification zone to produce a solidcarbon-depleted syngas product. The gasification reaction preferablyoccurs on the surface of a gasification reaction support structure andmay be catalysed.

The process further comprises endothermically reforminghydrocarbon-containing fuel gas with steam over a catalyst in a heatexchange reformer to produce a heat exchange-reformed syngas product. Atleast a portion of the heat required in the generation of said heatexchange-reformed syngas product is obtained by recovering heat fromsaid reacted syngas product thereby cooling the reacted syngas product.Use of this heat in this way provides further overall cooling of thesyngas. The heat exchange-reformed syngas product may be combined withthe reacted syngas product prior to heat recovery.

When the reactive diluent fluid is a gas, the exothermically-generatedsyngas product is first cooled via sensible heat exchange. When thereactive diluent fluid is a liquid, initial cooling occurs viavaporisation and sensible heat exchange. The reactive diluent fluid maybe recovered and recycled from downstream processing of syngas. Thereactive diluent fluid may promote the gasification of any solid carbonparticles or soot present in the reactive mixture. The reactive diluentfluid may be imported from an external source.

The reactive diluent fluid preferably comprises carbon dioxide. Anadvantage of using carbon dioxide as the diluent is that it may bereadily converted to more useful carbon monoxide via a reverse water-gasshift reaction (see reaction (III)), resulting in more carbon monoxidebeing available for downstream processing. In addition, if the carbondioxide has been recycled from downstream processes, the potentialemission level of this greenhouse gas is reduced.

The reactive diluent fluid may comprise carbon dioxide separated, e.g.by acid gas recovery and recycled from downstream syngas or recoveredand recycled from downstream processing of syngas. Alternately, theresidual gas from a GTL reactor comprising carbon dioxide can berecycled without processing in an AGR unit. The reactive diluent maycomprise the products of a combustion process which would contain asignificant quantity of carbon dioxide. The combustion products may beselected from the group consisting of combustion furnace flue gases andgas turbine exhaust gas. The reactive diluent fluid may comprise carbondioxide imported from an external source. For certain applications, thereactive diluent fluid may comprise carbon dioxide and methane eitheralone or together with other hydrocarbon(s) such as ethane, propane,butane, pentane, hexane and/or their isomers. In a typical F-T based GTLprocess, the diluent may be a residual effluent of the reactor afterseparation of synfuel and water. In this case, it would comprise ofcarbon dioxide, unreacted carbon monoxide and molecular hydrogen, lowmolecular weight paraffins, olefins and oxygenates. The recycling ofthese gases increases their utilization and increases the overall GTLprocess efficiency.

The reactive diluent fluid may comprise molecular hydrogen. Theinjection of hydrogen into the first syngas product pushes the positionof the equilibrium in reaction (III) in a reverse water gas shiftreaction towards the carbon monoxide product side. This effect isadvantageous because it promotes the conversion of carbon dioxide tocarbon monoxide.

The use of carbon dioxide or molecular hydrogen as diluent isadvantageous as both gases are capable of promoting the gasification ofcarbon components in the mixture of cooled exothermically-generatedsyngas product and reactive diluent fluid.

The reactive diluent fluid may comprise water. The water may be in theform of liquid water or steam or may comprise a combination of liquidwater and steam. The injection of water is primarily to promote thegasification of carbon components in the mixture of cooledexothermically-generated syngas product and reactive diluent fluid.

The reacted syngas product from the reformer or a syngas mixture derivedtherefrom is preferably used in a downstream conversion process toproduce conversion products selected from the group consisting ofhydrocarbon liquid fuels, methanol, DME and oxo-alcohols.

In another embodiment of the present invention, a second diluent fluidis combined with the syngas stream between the point at which thereactive diluent fluid is combined with the exothermically-generatedsyngas product and the point at which heat is recovered from the reactedsyngas product to adjust the temperature and/or change the compositionof the relevant gas stream.

The second diluent fluid may change the composition of the gas streamentering the shellside of a heat exchange reformer such that performanceof the heat exchange reformer is enhanced. In another arrangement, thesecond diluent fluid may adjust the temperature of the gas streamentering the shellside of the heat exchange reformer such that the heatexchange reformer operates in a more desired temperature range.Composition change and/or temperature adjustment are achieved throughphysical/thermal mixing or/and reactions between the said reacted syngasproduct and the second diluent fluid.

The second diluent fluid may be combined with the reactive mixture inany section of the second reactor or may be combined with the reactedsyngas product at any point between the second reactor and the heatexchange reformer. Where the heat exchange reformer is a shell and tubestyle reformer in which the endothermic reforming reaction occurs withinthe tubes and the reacted syngas product is introduced to theshell-side, the second diluent fluid is introduced in any section of theshell-side of the heat exchange reformer.

The second diluent fluid may be inert or reactive. The fluid may beselected from the group consisting of water vapor, steam, liquid water,molecular hydrogen, carbon dioxide, methane (and other light (e.g. C2 toC6) hydrocarbons), offgas from downstream processes, and othersubstances (previously identified) that could enhance the performance ofthe heat exchange reformer and could adjust its operating temperature.

Water and/or steam may be combined as the second diluent with thereacted syngas product to reduce the amount of metal dusting inside theheat exchange reformer and/or to adjust the temperature of the reactedsyngas product. Such injection of water and/or steam increases the waterconcentration of the gas stream to the shellside of a heat exchangereformer. This increase in the water concentration reduces the severityof metal dusting conditions inside the heat exchange reformer. Waterand/or steam can also adjust the temperature of the gas stream to theshellside of a heat exchange reformer to meet requirements of thereformer operation. The temperature, amount, and form of the water orsteam (i.e. gaseous or liquid) can be selected to fit the needs of theheat exchange reformer.

Molecular hydrogen may be combined as the second diluent fluid with thereacted syngas product to enhance the heat exchange efficiency inside aheat exchange reformer. A recycle molecular hydrogen stream can beestablished as the second diluent. Due to the much greater heatconductivity of molecular hydrogen compared to other gases, theresulting hydrogen-rich environment can enhance the heat exchangeefficiency inside a heat exchange reformer, thereby reducing the sizeand capital cost of the reformer.

The selection of the point at which the second diluent is introduceddepends on the specific needs of a process. The injection can be madeinto any section of the second reactor comprising the shift reactionzone and/or the gasification zone, any section of the shellside of aheat exchange reformer, and between the second reactor and the heatexchange reformer. In the arrangement where steam is introduced tomitigate metal dusting inside a heat exchange reactor and adjust thetemperature of the gas stream to the reformer, the injection point maybe between the exit of the second reactor and the entrance to theshellside of the heat exchange reformer. Alternatively, if the objectiveof steam injection is only for mitigating metal dusting, steam can beintroduced into the section of the heat exchange reformer where metaldusting may occur, namely the section where temperature drops below thecarbon precipitation temperature.

The selection of injection point impacts on the performance and cost ofa process. By way of comparison, introducing steam to the effluent ofthe primary reformer or to the tube side of the heat exchange reformercan also reduce metal dusting severity and/or adjust temperature.However, these two introduction points result in additional carbondioxide in the syngas product due to water gas shift reaction in eitherthe second reactor or inside the tubes of the heat exchange reformer.Increased carbon dioxide concentration results in higher carbon dioxideseparation cost and/or negative impact on downstream processes. Theinjection of steam between the second reactor and the heat exchangereformer, as proposed by the above mentioned arrangement, does notproduce additional carbon dioxide.

In a second aspect of the present invention, there is provided a processfor the production of syngas comprising carbon monoxide and molecularhydrogen, said process comprising;

exothermically reacting hydrocarbon-containing fuel with an oxidant gascomprising molecular oxygen in a first reactor to produce anexothermically-generated syngas product;

cooling an effluent stream of said exothermically-generated syngasproduct by combining reactive diluent fluid with said stream to producea mixture comprising cooled exothermically-generated syngas product andreactive diluent fluid, said mixture further comprising at least onecomponent selected from the group consisting of carbon dioxide and solidcarbon particles; said process further comprising:

reacting together carbon dioxide in said mixture with molecular hydrogenin said mixture over a catalyst in a second reactor to produce a reactedsyngas product that is enriched in carbon monoxide; and/or

gasifying solid carbon particles in said mixture with at least one othercomponent in said mixture in a second reactor to produce a reactedsyngas product that is depleted in solid carbon.

The step of the process to produce solid carbon-depleted syngas can becarried out instead of the step to produce carbon monoxide-enrichedsyngas and vice versa. Alternatively, the two steps can be carried outeither sequentially or simultaneously. Preferably, the reacted syngasproduct is both enriched in carbon monoxide and depleted in solidcarbon.

This process may also comprise endothermically reforminghydrocarbon-containing fuel gas with steam over a catalyst in a heatexchange reformer to produce a heat exchange reformed syngas productwherein at least a portion of the heat generated in the exothermicreaction producing said exothermically generated syngas product is usedto drive the endothermic reforming reaction.

In a third aspect of the present invention, there is provided apparatusfor the production of syngas comprising carbon monoxide and molecularhydrogen according the process of the first aspect, said apparatuscomprising:

a first reactor in which hydrocarbon-containing fuel is reactedexothermically with an oxidant gas comprising molecular oxygen toproduce an exothermically-generated syngas product;

conduit means for removing an effluent stream of saidexothermically-generated syngas product from the first reactor;

means for combining a stream of reactive diluent fluid with saideffluent stream to produce a reactive mixture;

a second reactor in which said reactive mixture reacts to produce areacted syngas product;

a heat exchange reformer in which hydrocarbon-containing fuel gas isreformed endothermically with steam over a catalyst to produce a heatexchange-reformed syngas product; and

conduit means for feeding a stream of reacted syngas product from thesecond reactor to the heat exchange reformer, wherein at least a portionof the heat required in the generation of said heat exchange-reformedsyngas product is obtained by recovering heat from said reacted syngasproduct thereby cooling the reacted syngas product.

The first reactor is preferably selected from the group consisting of aPDX reactor, an ATR or a CPO reactor.

Where the reactive mixture comprises carbon dioxide, the second reactorpreferably has a reverse water gas shift reaction zone in which at leasta portion of the carbon dioxide and at least portion of the molecularhydrogen in the reactive mixture are reacted together over a catalyst toproduce a carbon monoxide-enriched syngas.

Where the reactive mixture comprises solid carbon particles, the secondreactor may have a gasification reaction zone in which at least aportion of the solid carbon particles is gasified by reaction with atleast one other component of the reactive mixture to produce a solidcarbon-depleted syngas.

The reformer is preferably a shell and tube style reformer in which theendothermic reforming reaction occurs within the tubes and the reactedsyngas product is introduced to the shell-side. Most preferably, thereformer is an EHTR.

The apparatus may further comprise means for combining a second diluentfluid with a syngas stream between the point at which the reactivediluent is combined with said exothermically-generated syngas productand the point at which heat is recovered from the reacted syngas productto adjust the temperature and/or change the composition of relevantsyngas stream.

In a fourth aspect of the present invention, there is provided apparatusfor the production of syngas comprising carbon monoxide and molecularhydrogen according to the process of the second aspect, said apparatuscomprising:

a first reactor in which hydrocarbon-containing fuel is reactedexothermically with an oxidant gas comprising molecular oxygen toproduce an exothermically-generated syngas product;

a second reactor;

conduit means for feeding an effluent stream of said exothermicallygenerated syngas product from the first reactor to the second reactor;

means for combining reactive diluent gas with said effluent stream toproduce a mixture comprising cooled exothermically-generated syngasproduct and reactive diluent gas, said mixture further comprising atleast one component selected from the group consisting of carbon dioxideand solid carbon particles;

said apparatus further comprising:

a reverse water gas shift reaction zone in which carbon dioxide in saidmixture is reacted together with molecular hydrogen in said mixture overa catalyst in the second reactor to produce reacted synthesis gasproduct that is enriched in carbon monoxide; and/or

a gasification reaction zone in which solid carbon particles in saidmixture are gasified with at least one other component in said mixturein the second reactor to produce reacted syngas product that is depletedin solid carbon.

The apparatus may further comprise:

a heat exchange reformer in which hydrocarbon-containing fuel gas isreformed endothermically with steam over a catalyst to produce a heatexchange reformed syngas product; and

conduit means for reacted syngas product from the second reactor to theheat exchange reformer,

wherein at least a portion of the heat generated in the exothermicreaction producing said exothermically generated syngas product is usedto drive the endothermic reforming reaction.

The first reactor is preferably a PDX reactor as this reactor producesthe highest temperature syngas (when compared with ATR and CPO) and thehigher the temperature of the syngas from the primary heat-generatingunit, the higher the conversion of carbon dioxide in the reactivediluent and the better the efficiency of downstream HER processing. ThePDX reactor is preferably used in combination with an EHTR as the heatexchange reformer.

EXAMPLE

Referring to FIG. 1, a stream 2 of natural gas is preheated by indirectheat exchange 8, hydrodesulfurized as required, and divided into a firstportion 4 and a second portion 6. The first portion 4 is introduced intoa PDX reactor 12. A stream 14 of oxygen is pre-heated by indirect heatexchange 16 and the pre-heated oxygen stream 18 is also fed to the PDXreactor 12. The natural gas and the oxygen are reacted together in thePDX reactor 12 to produce first syngas product. A stream 20 of firstsyngas product is removed from the PDX reactor 12 at a temperature offrom 1200 to 1400.degree. C.

A stream 22 comprising carbon dioxide is introduced to and cools thefirst syngas product stream 20. The cooled stream 24 is fed to a reversewater gas shift reactor 26 in which at least a portion of the carbondioxide from the cooled stream 24 is reacted with at least a portion ofthe hydrogen from the cooled stream 24 to produce carbon monoxide andwater. The catalytic reaction is endothermic and, thus, a furthercooling effect on the syngas is observed. A stream 28 of carbonmonoxide-enriched syngas is removed from the reverse water gas shiftreactor 26 and introduced to the shell-side of an EHTR 30.

A stream 32 of steam is introduced to the second portion 6 of thenatural gas and the combined stream 34 is pre-heated by indirect heatexchange 36. The pre-heated combined stream 38 is introduced to thetube-side of the EHTR 30. The tubes of the EHTR 30 contain conventionalsteam-methane reforming catalyst and the natural gas and the steam reactto form second syngas product. Heat from the shell-side of the EHTR 30provided at least in part by the carbon monoxide-enriched syngas, isused to drive the endothermic catalytic steam-methane reformingreaction.

The second syngas product leaving the tubes of the EHTR 30 is combinedwith the first syngas product to form a combined syngas product. Astream 40 of combined syngas product is removed for downstreamprocessing, in particular for the synthesis of hydrocarbon liquid fuels(e.g. by the F-T process), methanol (e.g. by the catalytic hydrogenationof carbon monoxide), oxo-alcohols and DME.

Tables 1 and 2 contains data for the composition of various streams inthe process of FIG. 1 calculated in a computer simulation.

TABLE 1 STREAM ID 2 4 6 18 20 22 STREAM NG FEED NG TO POX NG TO EHTR POXO₂ POX OUT FT OFFGAS Temperature ° C. 16 (60) 363 (685) 363 (685) 232(449) 1343 (2450)  38 (100) (F.) Pressure MPa 3.55 (515)  3.41 (494) 3.41 (494)  3.17 (463)  2.84 (412)  4.14 (600)  (psig) Mole Flow Kg 8411 (18542)  6564 (14471) 2111 (4653) 4167 (9187) 19693 (43416) 1014(2301) mol/h (lb mol/hr) Enthalpy −658.8 (−625.0) −391.7 (−371.6) −126.0(−119.5) 25.6 (24.3) −367.1 (−348.3) −412.0 (−390.9) MMX3/h (MMBtu/hr)STREAM ID 24 28 38 40 STREAM QUENCH CATBED OUT EBTR FEED EHTR OUTTemperature ° C. 1245 (2270) 1197 (2186) 310 (930)  390 (1094) (F.)Pressure MPa 2.84 (412)  2.84 (412)  3.34 (484)  2.84 (412)  (psig) MoleFlow Kg 20737 (45717)  20823 (451818)  6577 (14499) 30953 (68238) mol/h(lb mol/hr) Enthalpy −779.1 (−739.2) −779.1 (−719.1) −1112.0 (−1055.0)−1912.0 (−1814.0) MMX3/h (MMBtu/hr)

TABLE 2 STREAM ID 2 4 6 18 20 22 Mole Flow Kg mol/h (lb mol/hr) H₂ 199.864.2 11437.0 (446.4) (141.6) (25213.8) C1 7967.2 6028.8 1938.5 90.8(37564.4) (13290.9) (4273.5) (200.1) C2 265.8 201.3 64.7 (585.9) (443.4)(142.6) C3 45.4 34.4 11.3 (100.1) (75.8) (24.4) C4 15.2 0.5 3.7 (33.4)(25.3) (8.3) C5 5.0 3.8 1.2 (13.1) (8.4) (2.7) C6 3.4 2.5 0.8 (7.4)(5.6) (1.8) CD (CO₂) 59.7 45.2 14.5 336.4 1043.7 (131.6) (99.6) (32.0)(741.2) (2300.9) CM (CO) 6232.2 (13739.6) WA (H₂O) 1539.2 (3393.3) O₂4146.2 (9140.6) AR (Ar) 20.8 20.8 (45.9) (45.9) N₂ 48.8 36.9 11.9 36.9(107.5) (81.4) (26.2) (81.4) Mole percent H₂ 3.00% 3.00% 58.10% C194.70% 91.80% 91.80% 0.50% C2+ PRESENT PRESENT PRESENT CD (CO₂) 0.70%0.70% 0.70% 1.70% 100.00% CM (CO) 31.60% WA (H₂O) 7.80% O₂ 99.50% AR(Ar) 0.50% 0.10% N₂ 0.60% 0.60% 0.60% 0.20% STREAM ID 24 28 38 40 MoleFlow Kg mol/h (lb mol/hr) H₂ 11437.0 10784.3 64.2 16429.3 (25213.8)(23774.9) (141.6) (36219.7) C1 90.8 47.3 1938.5 397.9 (200.1) (104.3)(4273.5) (877.1) C2 64.7 (142.6) C3 11.1 (24.4) C4 3.7 (8.1) C5 1.2(2.7) C6 0.8 (1.8) CD (CO₂) 1380.1 597.0 14.6 970.6 (3042.5) (1316.1)(32.0) (2139.7) CM (CO) 6232.2 7058.9 8476.0 (13739.6) (15561.9)(18685.0) WA (H₂O) 1539.2 2278.8 4466.1 4609.8 (3393.3) (5023.9) 9845.9)(10162.6) O₂ AR (Ar) 20.8 20.8 20.8 (45.9) (45.9) (45.9) N₂ 36.9 36.911.9 48.8 (81.4) (81.4) (26.2) (107.5) Mole percent H₂ 55.20% 51.80%1.00% 53.10% C1 0.40% 0.20% 29.50% 1.30% C2+ PRESENT CD (CO₂) 6.70%2.90% 0.20% 3.10% CM (CO) 30.10% 33.90% 27.40% WA (H₂O) 7.40% 10.90%67.90% 14.90% O₂ AR (Ar) 0.10% 0.10% 0.10% N₂ 0.20% 0.20% 0.20% 0.20%

Referring now to FIG. 2, a syngas generation system 42 of the typedepicted in FIG. 1 is fed by a stream 2 of hydrocarbon fuel gas, astream 14 of oxygen or air and a stream 32 of steam. A stream 40 ofsyngas is removed from the syngas generation system 42 and fed to asyngas conversion system 44. The syngas conversion system 44 may use anF-T process to synthesize liquid hydrocarbons or involve the synthesisof methanol, DME or oxo-alcohols. A stream 46 of raw conversion productis removed from the syngas conversion system 44 and upgraded and refined50 to produce the liquid products 52.

A stream 22 of reactive diluent gas is recycled from the syngasconversion system 44 to the syngas generation system 42. A recyclestream 54 may also be taken from the product upgrading and refiningprocess 50.

Referring now to FIG. 3, a stream 14 of oxygen and a stream 10 ofnatural gas are fed to a reactor 12 in which syngas is generatedexothermically. A stream 20 of exothermically generated syngas productis removed from the reactor 12. A stream 22 of a first reactive diluentis injected into the syngas product stream 20 to form a combined stream24 which is fed to a second reactor 26 in which either or both of areverse water gas shift reaction and a gasification reaction take place.A stream 28 of reacted syngas product is removed from the second reactor26 and is combined with a stream 56 of a second diluent fluid to form acombined stream 58 which is fed to a shell-and-tube style heat exchangereformer 30. The second diluent fluid may adjust the temperature of thereacted syngas product and/or change the composition of the reactedsyngas product which, inter alia, helps the reformer 30 to operate moreefficiently.

A stream 38 of natural gas is fed to the tube side of reformer 40 whereit is reacted endothermically in the presence of steam to produce asecond syngas product. Combined stream 58 is fed to the shell side ofthe reformer and, thus, heat originally from the exothermic generationof syngas is used to drive the endothermic syngas generation reaction. Astream 40 of combined syngas product is removed from the reformer 30 andfurther processed.

Throughout the specification, the term “means” in the context of meansfor carrying out a function is intended to refer to at least one deviceadapted and/or constructed to carry out that function.

It will be appreciated that the invention is not restricted to thedetails described above with reference to the preferred embodiments butthat numerous modifications and variations can be made without departingfrom the spirit or scope of the invention as defined in the followingclaims

What is claimed is:
 1. A process for the production of syngas comprisingcarbon monoxide and molecular hydrogen, said process comprising:exothermically reacting hydrocarbon-containing fuel with an oxidant gascomprising molecular oxygen in a first reactor to produce anexothermically-generated syngas product, the exothermically-generatedsyngas product having a first concentration of carbon monoxide;combining an effluent stream of the exothermically-generated syngasproduct with reactive diluent fluid with to produce a mixture comprisingcooled exothermically-generated syngas product and reactive diluentfluid, the mixture including carbon dioxide, molecular hydrogen andsolid carbon particles; reacting the carbon dioxide and the molecularhydrogen in the mixture over a catalyst in a second reactor to producereacted syngas product having a second concentration of carbon monoxidegreater than the first concentration; and gasifying solid carbonparticles in the mixture with at least one other component in themixture to produce reacted syngas product.
 2. The process of claim 1,further comprising endothermically reforming hydrocarbon-containing fuelgas with steam over a catalyst in a heat exchange reformer to produceheat exchange-reformed syngas product wherein at least a portion of theheat generated in the exothermic reaction drives at least a portion ofthe endothermic reforming reaction.
 3. The process of claim 1, whereinthe first reactor comprises a partial oxidation reactor.
 4. The processof claim 1, wherein the reactive diluent fluid comprises carbon dioxide.5. Apparatus for the production of syngas, comprising: a first reactorconfigured to exothermically react hydrocarbon-containing fuel with anoxidant gas including molecular oxygen to produce anexothermically-generated syngas product; a first conduit configured toremove an effluent stream of the exothermically-generated syngas productfrom the first reactor; a combining element configured to combinereactive diluent fluid with the effluent stream to produce a reactivemixture; a second reactor configured to react components of the mixtureto produce a reacted syngas product; a second conduit configured to feeda stream of reacted syngas product from the second reactor to a heatexchange reformer; and the heat exchange reformer configured toendothermically reform hydrocarbon-containing fuel gas with steam over acatalyst to produce a heat exchange-reformed syngas product, wherein theheat exchange reformer uses heat generated in the first reactor to driveat least a portion of the reforming.
 6. The apparatus of claim 5, thefirst reactor at least one of a partial oxidation (“PDX”) reactor, anautothermal reformer (“ATR”), or a catalytic partial oxidation (“CPO”)reactor.
 7. The apparatus of claim 5, the reactive mixture includingcarbon dioxide and molecular hydrogen, the second reactor including areverse water gas shift reaction zone configured to react, over acatalyst, at least a portion of the carbon dioxide and at least portionof the molecular hydrogen in the mixture to produce a carbonmonoxide-enriched syngas product.
 8. The apparatus of claim 5, thereactive mixture including solid carbon particles, the second reactorincluding a gasification reaction zone configured to react at least aportion of the solid carbon particles with at least one other componentin the mixture to gasify at least a portion of the solid carbonparticles.
 9. The apparatus of claim 5, the heat exchange reformercomprising a shell and tube style reformer including tubes an a shellside, the tubes configured to endothermically reformhydrocarbon-containing fuel gas with steam over a catalyst, the shellside introduces the reacted syngas product to heat the tubes for theendothermic reforming.
 10. The apparatus of claim 5, the reformercomprising an enhanced heat transfer reformer (“EHTR”).
 11. Theapparatus of claim 5, the combining element comprising a first combiningelement, further comprising a second combining element configured tocombine a second diluent fluid with a syngas stream after combining thereactive diluent and the exothermically-generated syngas product andprior to recovering heat from the reacted syngas product.
 12. Apparatusfor the production of syngas, comprising: a first reactor configured toexothermically react hydrocarbon-containing fuel with an oxidant gas toproduce an exothermically-generated syngas product, the oxidant gasincluding molecular oxygen; a second reactor; a conduit configured tofeed an effluent stream of the exothermically generated syngas productfrom the first reactor to the second reactor; an element configured tocool the exothermically-generated syngas product by combining reactivediluent gas with the effluent stream, the mixture including carbondioxide and solid carbon particles; a reverse water gas shift reactionzone in the second reactor configured to react the carbon dioxide andthe molecular hydrogen in the mixture over a catalyst, the reverse watergas shift reaction increases a carbon monoxide concentration of themixture; and a gasification reaction zone in the second reactorconfigured to react the carbon particles with at least one othercomponent in the mixture, the gasification reaction decreases aconcentration of the solid carbon.
 13. The apparatus of claim 12,further comprising: a heat exchange reformer configured toendothermically reform hydrocarbon-containing fuel gas with steam over acatalyst to produce a heat exchange reformed syngas product; and conduitconfigured to feed reacted syngas product from the second reactor to theheat exchange reformer, wherein the endothermic reforming uses at leasta portion of the heat generated in the exothermic reaction.
 14. Theapparatus of claim 13, the reformer comprises an EHTR.
 15. The apparatusof claim 12, the first reactor comprises a PDX reactor.